Downhole adjustable mud motor

Abstract

A downhole adjustable mud motor for boring wellbores, such as a hole in the earth. The downhole adjustable mud motor has a progressive cavity power section with a power cavity end, wherein the progressive cavity power section has a rotor rotatably captured within a stator and a plurality of fluid flow paths between the stator and the rotor for flowing drilling fluid. A power transmission section can be connected to the power cavity end having a central axis and an offset axis. A first adjustable member can be fastened to the stator. A second adjustable member can have a locking member, a bearing assembly connecting to the transmission assembly, and a fastener operatively connected to the bearing assembly. The locking member prevents compression of the second adjustable member inside of the first adjustable member when drilling fluid flows through the downhole adjustable mud motor.

What is claimed is: 
     
       1. A downhole adjustable mud motor for boring a hole in the earth comprising:
 a. a progressive cavity power section with a power cavity first end, the progressive cavity power section comprising:
 1. a rotor rotatably captured within a stator; and 
 2. a plurality of fluid flow paths between the stator and the rotor for flowing drilling fluid; and 
 
 b. a power transmission section connected to the power cavity first end, having an axis and an offset axis, the power transmission section comprising:
 1. a transmission assembly engaging the rotor; 
 2. a first adjustable member fastened to the stator; 
 3. a second adjustable member configured to simultaneously slide and rotate within the first adjustable member, wherein the second adjustable member comprising a locking member; 
 4. a bearing assembly connected to the transmission assembly; and 
 5. a fastener operatively connected to the bearing assembly, wherein the fastener engages an operating member enabling the downhole adjustable mud motor to operate the operating member; and 
 
 wherein the second adjustable member is configured to compress inside of the first adjustable member when weight is applied to the operating member and no drilling fluid is flowing through the downhole adjustable mud motor; further wherein the second adjustable member is configured to expand from the first adjustable member when the drilling fluid flows through the downhole adjustable mud motor to the operating member engaging the locking member, wherein the locking member prevents compression of the second adjustable member inside of the first adjustable member when the drilling fluid flows through the downhole adjustable mud motor. 
 
     
     
       2. The downhole adjustable mud motor of  claim 1 , comprising a pressure control valve located in a sub, wherein the sub is fastened to the stator, wherein the pressure control valve is configured to receive the drilling fluid from a surface location and transfer the drilling fluid to the stator, wherein the pressure control valve having a first position for receiving the drilling fluid from a first pair of flow ports and a second pair of flow ports and a second position for receiving the drilling fluid from only the second pair of flow ports, and further wherein the pressure control valve creating a pressure differential that indicates an angular position between the first adjustable member and the second adjustable member. 
     
     
       3. The downhole adjustable mud motor of  claim 1 , wherein the operating member includes the fastener to engage the power transmission section, wherein the fastener comprises a bit box, a box fitting, or a pin connection. 
     
     
       4. The downhole adjustable mud motor of  claim 1 , wherein the operating member is a drill bit or a heating element. 
     
     
       5. The downhole adjustable mud motor of  claim 1 , wherein the second adjustable member rotates within the first adjustable member from 0 degrees to 90 degrees along the offset axis. 
     
     
       6. The downhole adjustable mud motor of  claim 1 , wherein the second adjustable member slides within the first adjustable member along the offset axis from 5 inches to 60 inches. 
     
     
       7. The downhole adjustable mud motor of  claim 1 , wherein the rotor comprises from a 1 lobe to a 9 lobe rotor. 
     
     
       8. The downhole adjustable mud motor of  claim 1 , wherein the stator and the rotor comprise a stage from 1 stage and 20 stages. 
     
     
       9. The downhole adjustable mud motor of  claim 1 , wherein the stator comprises from 2 lobes to 10 lobes. 
     
     
       10. The downhole adjustable mud motor of  claim 1 , wherein the stator is a plurality of stators and the rotor is a plurality of rotors. 
     
     
       11. The downhole adjustable mud motor of  claim 1 , wherein each of the fluid flow paths of the plurality of fluid flow paths transfer the drilling fluid at a rate from 60 gallons per minute to 2,000 gallons per minute. 
     
     
       12. The downhole adjustable mud motor of  claim 1 , wherein the first adjustable member is disposed partially around a central axis and partially around the offset axis, the first adjustable member has a first cylindrical housing containing a plurality of first splines, wherein the plurality of first splines are configured to bi-directionally move parallel to the central axis, and wherein the first cylindrical housing further comprises a grooved inner surface. 
     
     
       13. The downhole adjustable mud motor of  claim 12 , wherein the second adjustable member is disposed around the offset axis, the second adjustable member having a second cylindrical housing, the second cylindrical housing containing a plurality of second splines, wherein the plurality of second splines are configured to rotate around the offset axis to align and interlock with the plurality of first splines, further wherein the plurality of second splines create a rotational lock with the plurality of first splines simultaneously preventing rotational movement of the first adjustable member and the second adjustable member. 
     
     
       14. The downhole adjustable mud motor of  claim 13 , wherein each cylindrical housing comprises: steel, stainless steel, tungsten carbide, reinforced fiberglass, graphic composite, copper, alloys thereof, combinations thereof. 
     
     
       15. The downhole adjustable mud motor of  claim 13 , wherein each cylindrical housing ranges from 4 feet to 60 feet in length. 
     
     
       16. The downhole adjustable mud motor of  claim 13 , wherein the second cylindrical housing can be angled from 0.01 of a degree to 10 degrees from the offset axis. 
     
     
       17. The downhole adjustable mud motor of  claim 1 , wherein the locking member comprises a plurality of moveable locking balls, wherein each moveable locking ball of the plurality of moveable locking balls is installed in one of a plurality pockets in the second adjustable member, each moveably locking ball of the plurality of moveable locking balls is adapted to move partially from each of the pockets of the plurality of pockets to completely lock with a grooved inner surface of the first adjustable member preventing axial movement of both the first adjustable member and the second adjustable member. 
     
     
       18. The downhole adjustable mud motor of  claim 1 , wherein the transmission assembly comprises a connecting rod, wherein the connecting rod engaging the bearing assembly through a plurality of flexible couplings. 
     
     
       19. The downhole adjustable mud motor of  claim 18 , wherein the locking member is a locking sleeve that slides inside the second adjustable member over the connecting rod. 
     
     
       20. The downhole adjustable mud motor of  claim 1 , comprising a plurality of helical stepped channels in the second adjustable member, a plurality of detent pucks in the first adjustable member, wherein each detent puck of the plurality of detent pucks is from the first adjustable member and rotates the second adjustable member when the drilling fluid flows in each helical stepped channels in the plurality of helical stepped channels, and steps of the plurality of helical stepped channels prevent the detent pucks from moving bi-directionally.